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Approaching Polycarbonate as an LFT-D Material: Processing and Mechanical Properties.

Christoph Schelleis1,2, Benedikt M Scheuring3, Wilfried V Liebig3

  • 1Polymer Engineering, Fraunhofer Institute for Chemical Technology ICT, 76327 Pfinztal, Germany.

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This study explores polycarbonate (PC) composites reinforced with glass fibers (GFs) using the long-fiber thermoplastic direct (LFT-D) process. These materials show promising mechanical properties for applications like electric vehicle battery enclosures.

Keywords:
LFT-Dcompositefiber lengthglass fibermechanical propertiespolycarbonateprocess parameter selectionspecific mechanical energy

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Area of Science:

  • Materials Science
  • Polymer Engineering
  • Composite Materials

Background:

  • Long-fiber thermoplastic (LFT) materials offer versatile composite solutions.
  • Polycarbonate (PC) reinforced with glass fibers (GFs) is explored for advanced applications, including electromobility battery enclosures.
  • The direct LFT (LFT-D) process enables tailored material combinations.

Purpose of the Study:

  • To investigate the processing and mechanical properties of PC GF LFT-D materials.
  • To evaluate the influence of processing parameters on fiber length and material performance.
  • To assess the suitability of PC GF LFT-D for demanding applications.

Main Methods:

  • Two processing and compression molding approaches for PC GF LFT-D were developed.
  • Variations in screw speed and fiber roving configurations were tested.
  • Mechanical properties including tensile, bending, Charpy, and impact strength were characterized.

Main Results:

  • Average fiber lengths of approximately 0.5 mm were achieved across all tested settings.
  • Tensile modulus reached 10 GPa, with tensile strength exceeding 125 MPa.
  • Flexural modulus achieved up to 11 GPa, and flexural strength reached up to 216 MPa.

Conclusions:

  • Polycarbonate glass fiber long-fiber thermoplastic direct (PC GF LFT-D) demonstrates stable processability.
  • The material exhibits robust mechanical properties suitable for demanding applications.
  • PC GF LFT-D is a viable composite for the LFT-D process, particularly for electromobility components.